In today's automotive industry, internal combustion engines are under increasing pressure to meet higher standards in emissions, performance, reliability, and cost-effectiveness. As a result, the crankshaft—a critical component of the engine—continues to evolve alongside advancements in manufacturing techniques. Due to its complex geometry, asymmetry, and high precision requirements, the crankshaft is one of the most challenging parts to machine.
To address these challenges, Sandvik Coromant has established the Crankshaft and Camshaft Machining Center, working closely with industry partners and machine tool builders to develop and refine machining processes and tools. This collaboration ensures that manufacturers can achieve optimal results while maintaining efficiency and cost control.
The crankshaft plays a central role in all types of internal combustion engines, from small units used in gardening equipment to massive versions found in marine diesel engines. Each crankshaft is tailored to its specific application, making customization and flexibility essential in production. Automotive crankshafts, in particular, have seen significant improvements in design, materials, and manufacturing over the years, driven by the need for better environmental performance, reduced weight, and enhanced fuel efficiency.
Environmental regulations have further increased the complexity of crankshaft manufacturing. Modern engines are smaller and more efficient, often incorporating turbochargers and other technologies to reduce emissions without sacrificing power. This trend continues to shape the evolution of crankshaft design and machining methods.
Industry standards reflect the high expectations for crankshaft machining. For example, milling cutters used in automotive applications must have a runout of no more than 0.02 mm, and their tool life must be long and predictable to support high-volume production. These tools must process thousands of crankshafts between each change, with cycle times optimized to a few seconds per unit.
Materials used in crankshaft production are also becoming more challenging. High-tensile steel forgings and lighter, stronger isothermal ductile irons are now commonly used, requiring advanced cutting solutions. To meet these demands, Sandvik Coromant has developed specialized tools and insert geometries that ensure stability, precision, and efficiency.
At the German Crankshaft and Camshaft Machining Center, Günter Wermeister and his team have successfully implemented over 900 tools worldwide. Their expertise spans decades, starting with the introduction of unique milling cutters in the 1970s and evolving into comprehensive turning and milling solutions by the 1990s.
Today, with global vehicle production exceeding 60 million annually, there is a growing demand for improved engine performance, lower emissions, and greater efficiency. This has made crankshaft machining solutions more vital than ever.
According to Mr. Wermeister, successful crankshaft machining depends on a thorough analysis of factors such as throughput, cycle time, equipment capabilities, and tool change intervals. There is no one-size-fits-all solution; each application requires a customized approach. The complexity of the crankshaft means that different machining processes—such as turning, car-car pull, internal milling, and external milling—are used depending on the part’s size, material, and production volume.
Turning is a flexible method primarily used for concentric sections of the crankshaft, while car-car pull combines turning and pulling for eccentric parts. Internal and external milling are also widely used, especially for large or high-volume production runs.
Each machining method has its advantages, but they all require precise tooling, stable setups, and optimized cutting parameters to ensure consistent quality and minimal downtime. By continuously refining their tools and processes, Sandvik Coromant remains at the forefront of crankshaft machining, supporting the industry’s ongoing evolution.
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